200 ENGINE ASSEMBLY

The isolating oil pan gasket contains 12 integral locating/retaining cones which lock into holes drilled through the oil pan rails, and two large rectangular tabs located directly across from each other on the inner perimeter of the gasket. The cones keep the gasket properly located during oil pan installation, and the rectangular tabs serve as a starting point for locating the gasket on the oil pan rail.

When servicing an E7 engine with an isolating oil pan arrangement, avoid using an engine stand that supports the engine on the oil pan rail while the oil pan is still installed. Damage to the oil pan, pan gasket or the isolators may result. If this type of stand must be used and the oil pan is to remain installed, support the engine on the pads provided at each corner of the cylinder block as shown in Figure 6-56.

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200 Engine Assembly

Oil Pan Installation

1.Clean any oil from the cylinder block mounting surface and the oil pan rail. The oil pan must be installed dry.

Oil on the surface of the gasket or the rails of the cylinder block and oil pan during oil pan installation can cause the gasket to bulge out between any two bolts, particularly those at the mid-section corners. This condition may not occur immediately, but can do so at any time after installation. To avoid this occurrence, wipe any oil from the inner walls of the cylinder block crankcase and then clean the rails of the cylinder block and oil pan with a solvent such as lacquer thinner. Dry the cleaned surfaces completely.

2.Position the isolating oil pan gasket on the oil pan rails with ribbed side facing up.

3.Beginning at the center of the pan at one of the rectangular tabs, align rubber locating cones with corresponding holes in the oil pan rails.

4.In one motion, firmly press upper portion of the gasket with one hand while carefully pulling the rubber cone through the hole with the other hand until seated. Continue this procedure for the remaining locating cones.

5.After all cones have been installed, recheck to ensure they are all properly seated.

During removal of the isolating oil pan from the engine, the studs may have backed out while loosening the stud nuts. Be sure they are fully seated prior to installing oil pan.

6.When installing oil pan onto the engine, center the pan before tightening fasteners so that the edges of the metal isolator washers do not touch the pan. Refer to Figure 6-57.

Oil Pan Installation With New E7 Cylinder Blocks

Part numbers for E7 cylinder blocks with 8-mm tapped holes in the pan mounting rail are listed below. These are the service replacements for cylinder blocks with 10-mm tapped holes in the cylinder block oil pan rail.

Cylinder Block Assembly No. 239GB5517M

Cylinder Block Service Assembly No. 239GB5494C

With the introduction of these cylinder blocks, blocks with the 10-mm tapped holes in the cylinder block oil pan rail are no longer available.

The isolating oil pan gasket arrangement can only be used with cylinder blocks, timing gear covers and flywheel housings that have 8-mm tapped holes in the oil pan rail.

200 Engine Assembly

OIL PAN INSTALLATION WITH NEW E7 TIMING GEAR COVER AND FLYWHEEL HOUSING

A new timing gear cover with 8-mm holes for oil pan mounting was introduced with the 1994 certified E7-427 and E7-454 engines. This timing cover is used in conjunction with the isolating oil pan arrangement, but is also the service replacement for timing covers with 10-mm tapped holes for oil pan mounting. The new style timing gear cover part No. is 333GB285AM.

New flywheel housings with 8-mm tapped holes for oil pan mounting were also introduced on engines with the isolating oil pan gasket. As with the timing gear cover, the new housings are service replacements for flywheel housings with 10-mm tapped holes for oil pan mounting.

Two types of 8-mm studs will be supplied with all new timing gear covers and flywheel housing service assemblies. One type of stud is used if the engine has a fiber oil pan gasket, and the other type is used for engines with the isolating oil pan gasket.

When replacing a timing gear cover or a flywheel housing on an engine equipped with an isolating oil pan gasket, first remove the oil pan to prevent damaging the rubber isolating oil pan gasket. To prevent damaging the threads in the aluminum timing gear cover and the aluminum flywheel housing, be sure to use the designated studs rather than capscrews.

When servicing an old engine with 10-mm tapped holes in the oil pan mounting rail with a new cylinder block with 8-mm holes, reinstall the old oil pan and a new fiber oil pan gasket with 26 new 8-mm fasteners, No. 421GC293M, at the cylinder block and four 10-mm fasteners, No. 66AM4, at the timing gear cover and flywheel housing. Lubricate and torque fasteners No. 421GC293 to 24 lb-ft (33 N m) using torque wrench J 24406 or equivalent.

When servicing any engine with the fiber oil pan gasket (8-mm or 10-mm tapped holes in the cylinder block oil pan rail) and installing a new timing gear cover and/or a new flywheel housing, use the two standard studs, No. 107AM5019M, and two flange-head nuts, No. 191AM2, to attach the oil pan to the flywheel housing and/or the timing gear cover. Lubricate and torque stud nuts to 15 lb-ft (20 N m) using torque wrench J 24406 or equivalent. When servicing any engine with the isolating oil pan gasket (8-mm tapped holes in the cylinder block oil pan rail), and installing a new timing gear cover and/or flywheel housing, use the two shouldered studs, No. 616GC239M, with two flange-head nuts, No. 189AM1, with which the engine was originally built. Lubricate and torque shoulder bolts to 15 lb-ft (20 N m) using torque wrench J 24406 or equivalent.

[213 EV] CYLINDER HEADS Description

Each cylinder head is a one-piece casting covering three cylinders and securely held to the top of the cylinder block by special-head bolts. The inlet and exhaust valves, fuel injection nozzles and the engine compression brake housing assemblies (if equipped) are located in the cylinder heads. Valve seat inserts and valve guides are replaceable.

Cast-iron sleeves pass through the coolant cavity of the cylinder head at the center of each cylinder. The fuel injection nozzle holder assemblies are installed in these sleeves. The sleeve design and installation provides effective cooling for the fuel injection nozzles, valves and cylinder head. This sleeve also provides a sealed passage for the nozzle return-to-tank fuel, which passes from the nozzle sleeve chamber into a drilled fuel return passage in the cylinder head and back to the fuel tank.

The air inlet, coolant and exhaust manifolds are secured to the cylinder heads. The fuel inlet lines also enter the engine at the cylinder heads.

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Installation

200 Engine Assembly

Ensure that the cylinder heads are in acceptable condition. Refer to the cylinder head inspection procedures in the BENCH PROCEDURES section in this manual.

All MACK head gaskets are precoated and do not require any type of additional sealing compound.

Refer to Figure 6-58.

1.Place the head gaskets in position on the locating pins in the cylinder block deck.

2.Place a fire ring carefully in position on top of each cylinder sleeve.

Check that the design of the fire ring used is the correct match for the cylinder sleeves installed. Refer to the TROUBLESHOOTING section for Proper Fire Ring/Cylinder Top Combinations.

3.Position the completely assembled cylinder heads on the cylinder block. Locate the heads into the guide pins in the cylinder block.